System and method for converting ambient carbon dioxide to particulate carbon and oxygen

ABSTRACT

A system and method is described to convert ambient carbon dioxide (CO 2 ) to graphite and oxygen by splitting the carbon oxygen bonds. By using this process, CO 2  from point sources or from ambient air can be reduced or effectively eliminated, and thus the system can play an important role in the fight against CO 2  emissions and global warming. The system first introduces CO 2  and electrolyte solution to one or a series of specially designed pipes rotating pipes to create induction inside the pipes, resulting in breaking of the carbon-oxygen bonds and production of solid carbon and gaseous oxygen. The solid carbon and gaseous oxygen are then separated.

CROSS REFERENCE TO RELATED APPLICATION(S)

This document is a continuation-in-part of Niioka, U.S. patent application Ser. No. 12/072,059, filed Feb. 25, 2008, entitled “The Production Method of the Unit Which Carries Out a Disassembly and Separation for a Gas Molecular”, which claims priority to Japanese patent application 2007-149753, filed May 7, 2007, both of which are incorporated herein by reference in their entireties. This application also relates to Japanese patent applications Yoshio Niioka, Heisei 11-51310 and 2003-418708.

BACKGROUND

Carbon dioxide (CO₂) is the most prevalent, ubiquitous and cited greenhouse gas produced by anthropogenic activities. Greenhouse gases are widely believed to cause or at least significantly contribute to global warming, which in turn disrupts the integrity, stability and balance of the ecosystems (see Climate Change 2007: The Physical Science Basis. Contribution of Working Group I to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change.) Worldwide awareness of the detrimental effects of elevated CO2 on the environment has galvanized the world community to take concerted effort, as evidenced by the Kyoto Protocol, to control generation and release of anthropogenic carbon dioxide.

Due to the high energy barrier required to break the two bivalent bonds in carbon dioxide molecule (O═C═O), until the below described system and method, straight conversion of CO2 to harmless carbon particles and oxygen has never been a cost-effective approach or an energy-efficient proposition to reduce CO2 in ambient air. As a result, industrial operators and governmental policies have adopted the capture-and-sequestration approach as the best remedial technology to reduce ambient CO2 concentration in their fight against global warming.

SUMMARY OF THE INVENTION

The CO₂ conversion system described herein is designed to convert a significant fraction of CO₂ in a high CO₂ concentration input gas stream to constituent carbon (e.g., in graphite form) and oxygen. For example, in an exemplary configuration, the system takes less than 30 minutes to convert one cubic meter of high concentration (>99%, v/v) carbon dioxide under ambient condition to particular carbon, e.g., graphite (C) and oxygen (O₂).

Thus, a first aspect of the invention concerns a system for converting carbon dioxide to particulate carbon and oxygen. The system includes a CO2 conversion chamber which has at least one cylindrical chamber (referred to as a pipe) with rotating mixer (and preferably 2, 3, 4, 5, or more connected in series) within the chamber. A gas mixture containing CO2 (commonly at high concentration) and an electrolyte solution is delivered to the conversion chamber which converts at least a portion of the CO2 in the gas to particulate carbon (usually graphite) and oxygen in spent electrolyte solution. In fluid connection with the conversion chamber is a particulate carbon (e.g., graphite)-oxygen separation chamber which receives the spent electrolyte solution from the conversion chamber and separates the particulate carbon (e.g., graphite) from oxygen gas.

In highly advantageous embodiments, the electrolyte solution is a high pH aqueous solution of potassium hydroxide (KOH), silicon (Si), and silicic acid soda (Na₂O, nSiO₂, H₂O), e.g., mixed in approximately equal quantities; a filmy, gelatinous substance comprising a mixture of graphite, oxygen, un-processed CO₂ and electrolyte solution is produced by the conversion chamber.

In advantageous embodiments, the pipe includes a central shaft which has mixing projections extending from it (e.g., spiral shaped wings), such as 2, 3, 4, 5, 6, 7, 8, 9, or 10 such projections, or at least such specified number of projections; the shaft is coated with a corrosion and wear resistant material, e.g., a ceramic coating, thereby reducing its rate of wear and lengthening its life cycle in a highly corrosive environment.

In the particular embodiments, the pipe is filled with CO₂ and electrolyte solution and the mixer (e.g., mixing shaft) is spun at high speed. This causes friction to occur in the vicinity of the mixing projections because of constant movement and contact between electrolyte solution and edges of the mixing projections, such that an electrical field is generated from impulse and oscillation, and the pipe becomes inductive.

In advantageous embodiments, the separation chamber includes a centrifugal drum filter apparatus; graphite is separated from oxygen in the separation chamber by passing the mixture through spinning inductive filters that are filled with loose fiberglass fibers at one end and tightly packed fiberglass fiber rolls at the other end; the CO₂ conversion chamber and the graphite-oxygen separation chamber are fluidly linked together using two connecting pipes, and both chambers use an electrolyte solution that is prepared by dissolving potassium hydroxide (KOH), silicon (Si), and silicic acid soda (Na₂O, nSiO₂, H₂O) in a volume of water resulting in a high pH solution; the graphite-oxygen separation chamber includes a hollow, cylindrical filter drum made of layers of synthetic silicon resin, glued together with silicon resin adhesive and perforated with a multiplicity of tubular filters, wherein each tubular filter is filled with loose fiberglass fibers at one end and tightly packed fiberglass fiber rolls at the other end.

In certain embodiments, during use of the system a filmy, gelatinous substance which includes a mixture of graphite, oxygen, un-processed CO₂ and electrolyte solution is produced by the conversion chamber and is directed to the center of the filter drum, fresh electrolyte solution from an electrolyte solution tank is released to the center of the filter drum via a washing pipe, and the filter drum is spun at high speed, e.g., centrifuge speed.

In further such embodiments, spinning of the filter drum creates an inductive environment in the filter drum whereby graphite in the filmy, jelly substance is attracted and migrated to loose fibers of the tubular filters, and is washed off with electrolyte solution which is directed to an electrolyte solution storage tank and oxygen passes through the tubular filters and is then directed to an oxygen and un-processed CO₂ collection tank.

A related second aspect concerns a system for purifying polluted air. The system can be essentially as described for the preceding aspect, and includes an air pollutant conversion chamber which includes at least one pipe. During use of the system, the pipe contains electrolyte solution and a mixer in the pipe is rotated at high speed and the pipe becomes inductive so that upon introduction of polluted air (or air pollutant) to the pipe a filmy, gelatinous substance is produced containing constituents of at least one air pollutant, unprocessed air pollutant, and electrolyte solution. As for the preceding aspect, advantageously there may be a plurality of such pipes connected in series, e.g., 2, 3, 4, 5, or more. In fluid connection with the conversion chamber is a pollutant-gas separation chamber as described for the preceding aspect for the CO₂ conversion chamber or otherwise described herein. Usually the separation chamber includes a filter drum that separates a solid pollutant constituent from gas in the filmy, gelatinous substance under inductive conditions by spinning the filter drum at high speed, e.g., centrifuge speed.

In particular embodiments, the system commonly will also include a gas delivery network that introduces, circulates, regulates and maintains air pollutant and gas pressure at desired levels throughout the air pollution conversion system, a liquid delivery network that introduces, circulates, regulates and maintains pressure of fresh and spent electrolyte solution as well as colloid of air pollutant and electrolyte solution at desired levels throughout the air pollution conversion system, and a network of electrical devices which include motors, pumps, electromagnetic solenoids, valves, nozzles that control, maintain the flow and pressure of gas and liquid in the air pollution conversion system.

In certain further embodiments, during use of the system polluted air (or air pollutants) and electrolyte solution are introduced to the pipe, the polluted air or air pollutant is mixed with the electrolyte in the pipe, and a jelly, filmy substance is generated that contains a plurality of constituents of a target air pollutant, hydrogen or oxygen gas or both, un-processed air pollutant, and electrolyte solution.

In further embodiments, use of the system also includes directing the jelly, filmy substance generated in the air pollutant conversion chamber to the pollutant-gas separation chamber using pressure created by spinning the mixer in the pipe in the air pollutant conversion chamber.

In still further embodiments, use of the system further includes directing the filmy, gelatinous substance to the center of the filter drum, injecting fresh electrolyte solution from an electrolyte solution tank to the center of the filter drum via a washing pipe, and spinning the filter drum at high speed, e.g., centrifuge speed; the spinning of the filter drum that contains a mixture of constituents of at least one air pollutant, oxygen or hydrogen gas or both, unprocessed air pollutant, and electrolyte solution creates an inductive environment in the filter drum, whereby one or more constituents of the air pollutant in the filmy, jelly substance will be attracted and migrated to loose fibers of tubular filters in the filter drum, and, under such inductive condition gas in the filmy, jelly like substance passes through the tubular filters.

Another related aspect concerns a method for separating carbon dioxide to particulate carbon and oxygen by processing carbon dioxide in the system described for the first aspect above or otherwise described herein, thereby producing separated particulate carbon and oxygen gas.

Similarly, the invention concerns a method for purifying polluted air or of breaking down one or more air pollutants. The method involves processing the polluted air or air pollutants through a system as described for the second aspect above.

Additional embodiments will be apparent from the Detailed Description and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 A diagram depicting front view of a CO₂ Conversion System

FIG. 2 A diagram illustrating rear view of a CO₂ Conversion System

FIG. 3 A diagram that illustrates partial sectional view of CO₂ conversion chamber and graphite-oxygen separation chamber.

FIG. 4A (top) A diagram illustrating an assembly of graphite-oxygen separation filter without outer casings. FIG. 4A (bottom right) A diagram illustrating cutout view of a filter drum. FIG. 4A (bottom left) A diagram illustrating filmy, gelatinous substance appears around tubular filters

FIG. 4B A diagram illustrating design and construction of the graphite-oxygen separation chamber.

FIG. 5 A diagram illustrating design and construction of the CO₂ conversion chamber

FIG. 6A A diagram illustrating design and construction of three conductive pipes in series

FIG. 6B (top) A diagram illustrating an assembly of a CO₂ conversion chamber.

FIG. 6B (bottom) A diagram depicting outer view of a CO₂ conversion chamber

FIG. 7 Diagrams illustrating how supplemental parts 41P and 42P are installed onto shaft 31

FIG. 8 A diagram illustrating detail design of sleeve 34 and its related parts which support rotation of shaft 31.

FIG. 9 A diagram illustrating outer view of sleeve 34 and other associated parts that support rotation of shaft 31

FIG. 10 A diagram illustrating how an extraction tool is used to change supplemental parts of shaft 31.

FIG. 11 (top right) A diagram depicting a section of a completed filter drum. FIG. 11 (bottom right) A diagram illustrating a sandwich of silicon resin layers and tubular filters under construction. FIG. 11 (bottom left) A diagram depicting a fiber string rolls under construction. FIG. 11 (middle left) A diagram depicting a completed fiber string rolls that is ready to be inserted into tubular filter. FIG. 11 (top left) A diagram illustrating sectional view of tubular filters, jelly like films around tubular filters, and separation of graphite from oxygen in tubular filters.

FIG. 12 (right) A diagram depicting side view of a CO₂ conversion system. FIG. 12 (bottom left) A diagram depicting rear views of a CO₂ conversion system. FIG. 12 (top) A diagram depicting top views of a CO₂ conversion system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to a system and process for splitting the carbon oxygen bonds in carbon dioxide (CO₂) as well as in some air pollutants. The process results in separate particulate carbon (e.g., as graphite) and oxygen gas. The system and method described herein overcome current major technical challenges in reducing point source and/or ambient CO₂ concentrations. The system provides an advantageous way to reduce anthropogenic CO₂ emissions and reducing ambient CO₂, and therefore can play a key role in the fight against global warming.

The CO₂ conversion system and method described herein is a generally closed system which includes two key components:

A CO₂ conversion chamber;

A graphite-oxygen separation chamber.

As is readily recognized, the system will also include components for gas and liquid handling. Such components can vary depending on the design and application for a particular system. Generally there will be a gas delivery network which includes a CO₂ gas source and a series of distribution tubing and control components, e.g., tubing (often coated with a relatively non-reactive material such as Teflon®), valves, pressure regulators (e.g., that introduce, circulate, regulate and maintain pressure of CO₂ and O₂ at desired levels in the system) and the like.

Likewise there will generally be a corresponding liquid handling network which includes components for storing, circulating, and distributing liquids in the systems, including, for example, tanks, pipes, valves, pressure gauges that introduce, circulate, regulate, and maintain pressure of electrolyte solution and a mixture (which may be in a colloid) of CO₂ and O₂ at desired levels in the system.

The gas and liquid handling will usually be driven by a set of electrical and/or electromechanical devices (motors, pumps, pulleys, belts, .etc) that powers the CO₂ conversion system at desired speeds and pressures.

To convert CO₂ to graphite and oxygen under ambient condition, a gas with a high concentration of CO₂ and electrolyte solution described herein are introduced by their respective delivery systems at desired levels to a pipe or the first of a set of pipes, e.g., 3 pipes, in series that are housed in the CO₂ conversion chamber. Typically the gas and electrolyte solution are introduced separately but in coordinated fashion, e.g., simultaneously. To ensure adequate mixing and interaction between CO₂ and electrolyte solution in these inductive pipes, each pipe is constructed with mixer, e.g., a shaft with mixing projections such as wings fixed to the shaft and arranged so that the shaft can be spun at high speed. In particular embodiments, the shaft has spiral shaped wings (e.g., 5 wings) welded or otherwise fixed to the shaft. Rotation of the shaft at high speed is believed to induce magnetism inside the pipes. When acidic CO₂ is mixed with alkaline electrolyte solution under such high speed mixing conditions, a filmy, gelatinous substance appears in the CO₂ conversion chamber. While it is possible to design a system such that one or more of the pipes rotate (either instead of the shaft or in addition to the shaft such as in a counterrotating manner), in most cases it is simpler or more desirable to just rotate the shaft.

This jelly, filmy, gelatinous colloid is then directed to a graphite-oxygen separation chamber. A major component of the graphite-oxygen separation chamber is a filter. An advantageous configuration includes a hollow, cylindrical filter drum perforated with filters, e.g., tubular filters. For example, an exemplary filter drum is made of layers of synthetic silicon resin and perforated with bubular filers (182 such tubular filters in one case). In that example, each tubular filter is 35 mm in length, 15 mm in outside diameter with 10 mm inside diameter at the top, and 10 mm in outside diameter and 5 mm inside diameter at the bottom. Each tubular filter is tightly packed with fiberglass string roll at the top and loose fiberglass fibers at the bottom.

When the filter drum is spun at centrifuge speed inside the graphite-oxygen separation chamber, fresh electrolyte solution is injected to the center of the filter drum to create electrostatic induction that separates graphite from oxygen in the jelly like, filmy substance.

Under this condition, two reactions follow. First, graphite is attracted to loose fibers dangling from the bottom of tubular filters and is eventually washed and/or dislodged by electrolyte solution. Second, oxygen and un-processed CO₂ passes through the tubular filters that are tightly packed with fiber string roll.

Excessively high pressure created by introducing the jelly like substance to and/or spinning the filter drum in the graphite-oxygen separation chamber at centrifuge speed is prevented and managed by installing a network of electromagnetic valves e.g., solenoid valves), liquid discharge nozzles, and gas discharge nozzles in the system. Activation of electromagnetic valves and liquid relief nozzle allows 1) graphite as well as fresh and spent electrolyte solution to be collected at electrolyte solution tank and 2) gases, such as oxygen and un-processed CO₂, to flow to oxygen tank.

Conversion of CO₂ to graphite and oxygen under ambient condition is thus achieved.

Embodiments of a method and system for converting CO2 to carbon particles and oxygen under ambient condition will be understood more fully from the description given below and from the accompanying drawings of embodiments, which, however, should not be taken to limit the method and system to a specific embodiment, but are for explanation and understanding only. It will be recognized that variations can be made to the design within the scope of the invention.

As a preliminary matter, item identifiers used in the drawings are listed below.

ITEM IDENTIFIERS

-   1. CO₂ conversion chamber -   2 Graphite-oxygen separation chamber -   2 a Top half of graphite-oxygen separator casing -   2 b Bottom half graphite-oxygen separator casing -   2 c Magnet for solenoid valves. -   3 CO₂ cylinder with a certified concentration -   4 a Electrolyte solution tank -   4 b Electrolyte solution spare tank -   4 c Location of electrolyte solution injection nozzle -   5. Collection tank for oxygen and un-processed CO₂ -   6 a, Connecting pipe between CO₂ conversion chamber and     graphite-oxygen separation chamber -   6 b Connecting pipe between CO₂ conversion chamber and     graphite-oxygen separation chamber -   7 a Electric motor that powers rotation of filter drum -   7 b Pulley -   7 c Belt -   7 d Electric motor to rotate shaft 31 -   8 a Pump that pumps electrolyte solution to graphite-oxygen     separation chamber -   8 b Pipe for electrolyte solution -   9 Door for changing filter drum -   10 Tubing connecting CO₂ tank to CO₂ conversion chamber -   10 a Location of carbon dioxide injection nozzle -   10 b Pipe with valve to drain excessive electrolyte solution from     CO₂ conversion chamber -   10 c Pipe with valve to drain excessive electrolyte solution from     CO₂ conversion chamber -   11 a Tubing that leads gases from graphite-oxygen separation chamber     to tank 5 -   11 b Pressure regulation valve -   11 c Pressure regulation valve -   12 Stand that supports CO₂ conversion system -   13 a Cover of CO₂ conversion chamber -   13 b Cover of CO₂ conversion chamber -   13 c Drainage nozzle -   13 d Drainage nozzle -   14 A coupling to connect shaft -   15 a Shield packing -   15 b Shield packing -   16 a Bearing -   16 b Bearing -   17 a Shaft for the rotation drum -   17 b Connection shaft -   18 a Main body of the centrifuge-separator rotation drum -   18 b Filter cover -   19 Contact surface between the rotating drum and connecting pipes -   20 Cap to prevent leakage of exhaust gas -   21 a Inductive filter drum that separates graphite from O₂ -   21 b Jet that discharges fresh electrolyte solution to filter drum     to dislodge graphite from fibers and to prevent tubular filters from     clogging -   21 c Liquid discharge nozzle -   22 Gas discharge nozzle -   23 a Cross section of filter drum and graphite-oxygen separator -   23 b Electromagnetic valve -   24 Electrolyte solution drainage pipe -   25 Bolt hole -   26 a Rotating spiral shaped wings that induce magnetism in pipe 29 a -   26 b Rotating spiral shaped wings that induce magnetism in pipe 29 b -   26 c Rotating spiral shaped wings that induce magnetism in pipe 29 c -   27 Nozzle that injects colloid of CO₂ and electrolyte solution from     pipe 29 c to interior of CO₂ conversion chamber -   28 a Connecting pipe between pipes 29 a and 29 b -   28 b Connecting pipe between pipes 29 b and 29 c -   28 c Flow direction of colloid of CO₂ and electrolyte solution     toward connecting pipe between 2 chambers -   28 g Flow direction of CO₂ toward pipe 29 a -   28 w Flow direction of electrolyte solution toward pipe 29 a -   29 a Inductive pipe caused by spinning electrolyte solution inside     at high speed -   29 b Inductive pipe caused by spinning electrolyte solution inside     at high speed -   29 c Inductive pipe caused by spinning electrolyte solution inside     at high speed -   30 Supplemental parts that ease wearing of shaft 31 -   31 Shaft -   31 a Shaft axis of pipe 29 a -   31 b Shaft axis of pipe 29 b -   31 c Shaft axis of pipe 29 c -   31 s Key of supplemental part 41 p -   32 Cap -   33 a Blind flange -   33 b Packing -   33 c Flange -   33 d Shaft lineup flange -   34 Sleeve main body -   35 a Bolt -   35 b Bolt -   36 Gland packing -   37 Washers -   38 Spring -   39 Cap for the sleeve main body -   40 Bearing attachment bracket -   40 a A piece of pipe serves as bearing receptacle and connection     pipes 6 a, 6 b. -   41 p Supplemental part with ceramic coating -   42 Supplemental part viewed from left side -   42 p Supplemental part with ceramic coating -   42 u Direction of extracting supplemental parts -   42 v Slot made on the supplemental part 42 p for attaching     extraction tool -   42 y Handle of an extraction tool -   42 z Extraction tool for changing supplemental parts -   43 Key seat -   44 Layer of silicon resin made of synthetic fibers -   45 a Synthetic silicon resin -   45 b Synthetic silicon resin adhesive -   46 Pile cut textile -   47 Tubular filter -   48 Side view of tubular filter showing a tapering bottom -   49 Flow direction of oxygen and CO₂ -   50 Tightly packed fiber string roll -   51 Loose fiberglass fibers -   52 Fiberglass fibers used in making filter strings -   53 Jelly like film resulting from mixing CO₂ and electrolyte     solution in inductive environment -   54 Black dots denote graphite in filmy, gelatinous substance being     attracted to tubular filters -   55 The side without CO₂ gas leak, gases all pass through tabular     filters

6-I Design And Setup of CO2 Conversion Chamber

FIG. 1 depicts the front view of an example of a fully integrated CO₂ conversion system. In the description below, the particular design, including dimensions, materials, numbers of particular components, and other characteristics of the system should be understood to be illustrative and not limiting.

The system consists of a CO₂ conversion chamber 1 and a graphite-oxygen separation chamber 2. To begin converting CO₂ to graphite and oxygen, CO₂ gas and electrolyte solution is injected separately but simultaneously to chamber 1 from a CO₂ source, e.g., cylinder 3, and an electrolyte solution tank 4 a through their delivery systems at desired levels. After conversion, the colloid of CO₂ and electrolyte solution is directed to graphite-oxygen separation chamber 2 via two connecting pipes 6 a and 6 b.

In this exemplary system, electrolyte solution storage tank 4 a is made of SUS 304 stainless steel. Its size is 590 mm in diameter, 900 mm in height and volume of about 200 liters. The size of the electrolyte auxiliary electrolyte storage tank 4 b is 490 mm in diameter and 600 mm in height and the volume is about 120 liters. It is made of SUS 304 stainless steel. The size of the oxygen collection tank 5 in FIG. 5 is 1200 mm in outside diameter and 1300 mm in height and is made of steel with the tank interior coated with epoxy resin.

There are four additional illustrations that provide overview of the CO₂ conversion system: FIG. 2 illustrates rear view of the CO₂ conversion system which sits on stand 12. FIG. 12 (bottom left) Rear view of the CO₂ conversion system. FIG. 12 (top) Top view of the CO₂ conversion system. FIG. 12 (bottom right) Side view of the CO₂ conversion system

FIG. 3 presents partial sectional view of the CO₂ conversion chamber 1 and graphite-oxygen separation chamber 2. The detailed design of filter drum 18 a in chamber 2 is illustrated in FIG. 4A and FIG. 4B which is discussed in sections III and IV below. The size of the CO₂ conversion chamber 1 is 1,600 mm in length and 600 mm in diameter. The size of cover 13 a is 300 mm in width and 600 mm in inside diameter and both covers are made of plastic material (FIG. 6B, bottom).

Inside the CO₂ conversion chamber 1, there are three pipes 29 a, 29 b, 29 c made of SUS-304 material (FIG. 5 and FIG. 6A). These pipes are specially designed, interconnected, and in series (29 a and 29 b are connected by 28 a; 29 b and 29 c are connected by 28 b) to ensure continuous mixing of CO₂ and electrolyte solution in the pipes. Five spiral shaped wings similar to that of 26 a are welded to shafts 31 a, 31 b and 31 c, respectively using argon gas welding process. The wings serve to enhance mixing and interaction of CO₂ with electrolyte solution in each pipe. Each set of five wings is labeled 26 a, 26 b, 26 c, respectively in FIG. 5.

The size of pipe 29 a, 29 b, and 29 c is 1,200 mm in length, 145 mm in outside diameter, 3.0 mm in thickness and make of SUS 304 stainless steel. Shaft 31 a, 31 b, 31 c is installed in the center of pipe 29 a, 29 b, and 29 c, respectively (FIG. 5). Supplemental parts 30 are installed to shaft 31 to ease its wearing (FIG. 6B, top). The size of shaft 31 a, 31 b, and 31 c is 1500 mm in length and 25 mm in diameter and is made of SUS-304 material. The size of the rotating electrode spiral shaped wings 26 a, 26 b, and 26 c is made of SUS-304 material and 150 mm in length and 100 mm in outside diameter (FIG. 5).

A cap 32 with a 28 mm hole as shown in FIG. 6A is installed on each end of a pipe so that shafts 31 a, 31 b, 31 c can be extruded (a total of six caps on three pipes). Each cap is made and installed in such a way that CO₂ gas or electrolyte solution would not leak from the end of a pipe. Blind flanges 33 a, packing 33 b, shaft lineup flanges 33 d with three 28 mm holes, and flange 33 c with bolt holes 25 are constructed to support installation of three shafts 31 a, 31 b, and 31 c to the CO₂ conversion chamber 1 (FIG. 6B, top). Each end of CO₂ conversion chamber 1 is capped with a cover 13 a or 13 b and equipped with a drainage pipe 13 c or 13 d, respectively (FIG. 6B, top). Six bearings 16 a and other parts are designed and installed as shown in FIG. 8 to shafts 31 a, 31 b, and 31 c to provide smooth rotation.

An electrical motor 7 a with pulley 7 b and belt 7 c provide rotating power to the shaft in pipes 29 a, 29 b, and 29 c which quickly become inductive when CO₂ and electrolyte solution inside are spun at high speed (FIG. 6A).

Shaft 31 is installed in the center of sleeve 34, and shaft 31 is assembled with a gland packing 36, washer 37, spring 38, sleeve cap 39, bearing attachment bracket 40, shield packing 33 b, bolts 35 a, 35 b, and bearing 16 a. Rotation of shaft 31 is provided by an electric motor 7 d (FIG. 9).

A ceramic coating is applied to shaft 31 to slow down corrosion and wear of shaft 31. Due to extreme corrosive conditions in the CO₂ conversion chamber, average life cycle of shaft 31 without ceramic coating is only about 50 hours. This results in frequent change and service of shaft 31 as well as long periods of down time of the CO₂ conversion system.

Improvements are made to shaft 31 and its related components with a key 43 to prevent unauthorized service or tempering. First, a slot 42V is made on the edge of supplemental part 42P for attaching extraction tool. 42P is then inserted into shaft 31. Another supplemental part 41P is installed on the outside of part 42P (FIG. 7). A ceramic coating is applied to surfaces of shaft 31, 41P and 42P to a thickness of about 50 micrometer. Other thickness may also be selected depending on the particular application, e.g., about 20 to 50, 30 to 60, 40-70, or 50 to 100 micrometer. The material selected for the ceramic coating in this example is chromium oxide applied with plasma spraying equipment. The size for the supplemental part 42P is 50 mm outside diameter and 150 mm in length and made of SUS-304 material and the size for supplemental part 41P is 130 mm in length and 51 mm in outside diameter and also made of SUS-304 material. 42 is a supplemental part viewed from left side (FIG. 7).

With these improvements in place, the life cycle of shaft 31 has increased by about 100 times to 5,000 hours and shaft 31 and its associated components as those depicted in FIG. 7, FIG. 8, and FIG. 9 can now be readily retrieved, serviced and replaced with less time and effort. FIG. 10 illustrates how extraction tool 42 z can be used to remove supplemental parts. A technician can easily use handle 42 y to extract supplemental parts following the direction shown in 42 u.

6.2. Operations of CO2 Conversion Chamber

Electrolyte solution from tank 4 a is pumped by pump 8 a to CO₂ conversion chamber 1 while CO₂ from cylinder 3 is piped to CO₂ conversion chamber 1 via Teflon tubing 10 at its desired level by a pressure regulator 11 c (FIG. 1). Rotating speed of pump 8 a is determined by concentration of CO₂ in the chamber so that operator can control optimum mixing of CO₂ with electrolyte solution in pipes 29 a, 29 b and 29 c. For example, when 99.7% CO₂ is used, the motor speed that controls the flow rate of the electrolyte solution is set at 1,900 rpm. Excessive electrolyte solution is directed to electrolyte solution storage tank 4 a via overflow pipes 10 b and 10 c.

Specifically, electrolyte solution as described in herein is powered by pump 8 a in the direction as shown in 28 w to pipe 29 a through nozzle 4 c located at the center of pipe 29 a (FIG. 5). CO₂ is fed simultaneously but separately in the direction as shown in 28 g to pipe 29 a through nozzle 10 a located also in the center of pipe 29 a. As soon as the desired pressure for CO₂ and electrolyte solution is reached, power is then switched on to rotate the shafts in pipes 29 a, 29 b, and 29 c to make sure CO₂ and electrolyte solution freely flow past spiral shaped wings 26 a, 26 b, 26 c, thus enhance mixing interaction of CO₂ and electrolyte solution in the pipes.

Pipes 29 a, 29 b, and 29 c quickly become inductive when CO₂ and electrolyte solution inside are spun at high speed (FIG. 6A). In other words, when a colloid of CO₂ and electrolyte solution is mixed and treated this way, friction occurs in the vicinity of rotating spiral shaped wings due to constant movement and contact between electrolyte solution and edge of spiral shaped wings. An electrical field is generated from impulse and oscillation, and pipes 29 a, 29 b, 29 c become inductive.

It is theorized that under this environment, a majority of bipolar molecules in the electrolyte solution break down, generate cations and anions, and release exothermic energy that, under inductive condition, is sufficient to convert CO₂ to graphite and O₂. Hence the conversion of CO₂ to graphite and oxygen is successfully accomplished.

6.3 Design And Setup of Graphite-Oxygen Separation Chamber

When acidic CO₂ is mixed with alkaline electrolyte solution in pipes 29 a, 29 b, and 29 c in which shafts are spun at high speed, a filmy, gelatinous substance appears in these inductive pipes. This substance consisting of graphite, oxygen, electrolyte solution and un-processed CO₂ eventually reaches nozzle 27, which in turn injects this jelly, filmy substance to the interior of CO₂ conversion chamber 1 (FIG. 5). The filmy substance is then directed to graphite-oxygen separation chamber 2 via connecting pipes 6 a and 6 b (FIG. 4B). The size of the connecting pipes 6 a and 6 b in this exemplary system is 400 mm in length and 120 mm in outer diameter. These two pipes are installed horizontally to the right and left side of the graphite-oxygen separation chamber 2 (FIG. 4B).

A cross section of the filter drum and graphite-oxygen separator 23 a is shown in FIG. 4B. In this exemplary system, the main component inside the graphite-oxygen separation chamber 2 is a hollow, cylindrical rotation drum 18 a. The filter drum assembly 21 a in this case is made of layers of synthetic silicon resin 45 a glued together with silicon resin adhesive 45 b (FIG. 11, bottom right) and perforated with a large number of tubular filters 47 (FIG. 11, top right). In an exemplary system, one hundred and eighty two (182) tubular filters were used. Each layer of silicon resin is made of synthetic fibers 44 (FIG. 11, bottom right). The size of rotation drum 18 a in the exemplary system is 1,200 mm in length and the central drum diameter is 500 mm. It takes approximately 1,500 mm by 500 mm with 10 mm thickness of layers of synthetic silicon resin sandwich to construct a cylindrical, hollow rotating filter drum 21 a as seen in FIG. 4A (right bottom). The synthetic silicon resin sandwich is constructed as shown in FIG. 11 (right bottom) A synthetic fiber 44, a synthetic-resin silicon layer 45 a, and a synthetic silicon adhesive 45 b are stacked together with a pile cut fiber 46 to form the synthetic silicon resin sandwich. The filter drum is installed inside the rotation drum 18 a (FIG. 4A, top) and can be serviced or replaced through door 9 (FIGS. 1, 2). The size of plastic tubular filter 47 in the exemplary system is 35 mm in length, 15 mm in outside diameter with 10 mm inside diameter at the top, and 10 mm in outside diameter with 5 mm inside diameter at bottom.

The rotation drum 18 a is firmly positioned and framed by two casings: upper half casing 2 a and lower half casing 2 b. The contact surface between the rotation drum and connecting pipe 19 connects the outer body 40 a and the cap 20 to prevent gas leakage (FIG. 4B). The filter drum is constructed by shaping synthetic silicon resin sandwich into circular form (FIG. 4A, bottom right). One hundred and eighty-two 14 mm holes are drilled through 3 layers of silicon resin. Plastic tubular filter 47 that packed with fiber string roll is then forcefully inserted to each hole. Synthetic silicon resin adhesive is used to seal surroundings of each tubular filter 47 (FIG. 4A, bottom right) to prevent gas leak 55.(FIG. 11)

The length of the upper casing 2 a and lower casing 2 b for filter drum 18 a is 1400 mm and the largest outside diameter is 600 mm (FIG. 4B).

Construction of tubular filter 47 is as follows. Fiberglass fibers are first made into strings 52 and then rolled tightly into a filter string roll 50 (FIG. 11, bottom left). Tightly rolled fiber roll 50 is then forcefully inserted from the top into tubular filter 47 (FIG. 11, top left). Due to a larger inside diameter at the top and smaller ID at bottom portion of tubular filter 47, (FIG. 11, top left), tightly packed fiber string roll 50 will fit tightly inside the full length of tubular filter while the bottom portion 48 of the tubular filter is dangling with loose fiberglass fibers 51 (FIG. 11, top left). Black dots in FIG. 11, top left denotes graphite particles. FIG. 11 (top right) shows a top view of a small section of the filter drum.

Two shield packings 15 a and 15 b (FIG. 4A, top) and two bearings 16 a and 16 b are installed on the shaft 17 a and connection shaft 17 b of the filter drum 18 a to provide a smooth rotation (FIG. 4B). Pipe 40 a serves as bearing receptacle to link with connection pipes 6 a and 6 b (FIG. 4B). An electrical motor 7 a with pulley 7 b and belt 7 c provides the rotating power to shaft 17 a which in turn rotates filter drum 18 a at centrifuge speed and causes the filmy substance from the CO₂ conversion chamber 1 to flow into graphite-oxygen separation chamber 2 via connecting pipes 6 a and 6 b (FIG. 4B).

6.4 Operations of Graphite-Oxygen Separation Chamber

When filter drum 18 a is spun at centrifuge speed inside the graphite-oxygen separation chamber 2, fresh electrolyte solution is injected via pipe 8 b to the center of the filter drum. Such operations make the filter drum 21 a inductive and facilitate separation of graphite from oxygen. (FIGS. 4A, top and bottom right) Electrolyte solution released from jet/nozzle 21 b (which is installed at the end of pipe 8 b) is used to wash and dislodge graphite from loose fibers and to prevent the tubular filters from clogging (FIG. 4A, top). Cap 20 is installed at each end of the filter drum assembly to prevent leakage of liquid and gas (FIG. 4A, top). Furthermore, because after long hours of operation the tubular filters may become clogged with graphite, a timer is preferably installed to control the washing operation.

With reference again to jelly, filmy substance 53 (FIG. 4A, bottom left) coming out of the CO₂ conversion chamber 1, this substance is redirected following the direction as shown in 28 c (FIG. 5) to the filter drum 18 a in the graphite-oxygen separation chamber 2 via connecting pipes 6 a and 6 b (FIG. 3). At this time, filter drum is spun at centrifuge speed and fresh electrolyte solution is injected from pipe 8 b to the center of filter drum (FIG. 4B). Just like what happens in the CO₂ conversion chamber, high speed spinning of filter drum that contains a colloid of graphite, oxygen, un-processed CO₂ and electrolyte solution made the filter drum inductive. Due to the high rotation speed and more electrolyte solution, the electrostatic induction created in the filter drum is typically stronger than the one in the CO₂ conversion chamber 1.

As a result, graphite in the colloid is attracted and migrates to loose fibers of tubular filters 47 (FIG. 4A, bottom left). Graphite is washed off from tubular filters in graphite-oxygen separation chamber 2 with electrolyte solution. The electrolyte solution that contains graphite eventually is fed to electrolyte solution storage tank 4 a. Introduction of jelly, filmy substance 53 from CO₂ conversion chamber 1 to graphite-oxygen separation chamber 2 via connecting pipes 6 a and 6 b and/or spinning of filter drum 18 a at centrifuge speed creates high pressure in the system. To prevent excessive build-up of high pressure in the system, an electronically controlled network of magnet for solenoid valve 2 c, electromagnetic valves 23 b, liquid discharge nozzle 21 c, and gas discharge nozzle 22 is installed to adjust gas pressure (FIG. 4B).

Deactivation or closure of 2 c and 23 b stops the flow of jelly, filmy substance to graphite-oxygen separation chamber 2. Activation of both valves allows graphite along with spent and fresh electrolyte solution plus trace of O₂ and un-processed CO₂ to be piped to electrolyte solution storage tank 4 a via liquid discharge nozzle 21 c. Activation of both 2 c and 23 b also allows oxygen 49 (which has passed through tubular filters 47, see FIG. 11, top left) along with un-processed CO₂ plus trace of electrolyte solution to be piped to collection tank 5 (FIG. 1) via gas discharge nozzle 22 (FIG. 4B) and Teflon tubing 11 a and valve 11 b (FIG. 1). Contents of tank 5 can be drained via pipe 24 (FIG. 2).

Another alternative embodiment of CO₂ conversion chamber 1 and graphite-oxygen separation chamber 2 described herein is air purification in any open and/or closed environment. Due to industrialization, many common pollutants from workplaces and communities are transported by air, and are often called airborne pollutants or simply air pollution (such as ozone, nitrogen dioxide, nitrogen oxides, sulfur dioxide, sulfur oxides, methane, carbon monoxide, hydrogen sulfide, aromatic hydrocarbons, chloro-hydrocarbons, chlorofluorocarbons, microorganisms, etc). Because of the hazardous and toxic nature of these pollutants, they pose significant threats to human health and human welfare, triggering the birth of the air purification industry/business.

Current prevailing air purification devices utilize chemical, physical and/or biological mechanisms including chemical reaction, interaction, conversion, breakdown, absorption, adsorption, physical filtration, and/or biological decomposition to destroy or reduce air pollutant concentrations in the air. Since the CO₂ conversion system described herein is capable of breaking down the strong carbon oxygen bonds in CO₂ (i.e. the double bivalent bond between O═C═O), the system and method described herein is applicable and can be readily applied to purify ambient air caused by air pollutants that can be converted or broken down with less bond energy than CO₂. The CO₂ conversion system described herein can be installed is closed and/or open environments including but not limited to power plants, refineries, cement production plants, chemical manufacturing plants, factories, food processing plants, industrial clean rooms, engine exhaust, workplaces, hospitals, schools, and streets to reduce air pollutants levels and provide clean air for people to enjoy.

All patents and other references cited in the specification are indicative of the level of skill of those skilled in the art to which the invention pertains, and are incorporated by reference in their entireties, including any tables and figures, to the same extent as if each reference had been incorporated by reference in its entirety individually.

One skilled in the art would readily appreciate that the present invention is well adapted to obtain the ends and advantages mentioned, as well as those inherent therein. The methods, variances, and compositions described herein as presently representative of preferred embodiments are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art, which are encompassed within the spirit of the invention, are defined by the scope of the claims.

It will be readily apparent to one skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention. For example, variations can be made in the particular materials used to construct the various components of the system. Thus, such additional embodiments are within the scope of the present invention and the following claims.

The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.

In addition, where features or aspects of the invention are described in terms of Markush groups or other grouping of alternatives, those skilled in the art will recognize that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group or other group.

Also, unless indicated to the contrary, where various numerical values or value range endpoints are provided for embodiments, additional embodiments are described by taking any 2 different values as the endpoints of a range or by taking two different range endpoints from specified ranges as the endpoints of an additional range. Such ranges are also within the scope of the described invention. Further, specification of a numerical range including values greater than one includes specific description of each integer value within that range.

Thus, additional embodiments are within the scope of the invention and within the following claims. 

1. A system for converting carbon dioxide to particulate carbon and oxygen, comprising a CO2 conversion chamber comprising at least one high speed rotating pipe within said chamber, wherein high concentration CO2-containing gas and electrolyte solution is delivered to said conversion chamber and at least a portion of the CO2 in said gas is converted to graphite and oxygen in spent electrolyte solution; and in fluid connection therewith, a graphite-oxygen separation chamber which receives said spent electrolyte solution from said conversion chamber, wherein particulate graphite is separated from oxygen.
 2. The system of claim 1, wherein said electrolyte solution is a high pH aqueous solution of potassium hydroxide (KOH), silicon (Si), silicic acid soda (Na₂O, nSiO₂, H₂O).
 3. The system of claim 2, wherein said potassium hydroxide, silicon, and silicic acid soda are added in approximately equal quantities.
 4. The system of claim 1, wherein a filmy, gelatinous substance comprising a mixture of graphite, oxygen, un-processed CO₂ and electrolyte solution is produced by said conversion chamber.
 5. The system of claim 1, wherein said pipe includes a central shaft comprising mixing projections.
 6. The system of claim 5, wherein said shaft is coated with ceramic coating thereby reducing its rate of wear and lengthening its life cycle in a highly corrosive environment.
 7. The system of claim 5, wherein said mixing projections comprise 5 spiral shaped wings.
 8. The system of claim 5, wherein said pipe is filled with CO₂ and electrolyte solution and is spun at high speed, whereby friction occurs in the vicinity of said mixing projection because of constant movement and contact between electrolyte solution and edges of said mixing projections, wherein an electrical field is generated from impulse and oscillation, and said pipe becomes inductive.
 9. The system of claim 1, wherein said CO₂ conversion chamber comprises three pipes interconnected in series with fluid connection, wherein each pipe contains a central shaft with mixing projections extending therefrom which rotate to thoroughly mix said electrolyte and said CO2 containing gas inside said pipes.
 10. The system of claim 1, wherein said separation chamber comprises a centrifugal drum filter apparatus.
 11. The system of claim 4, wherein graphite is separated from oxygen in said separation chamber by passing said mixture through spinning inductive filters that are filled with loose fiberglass fibers at one end and tightly packed fiberglass fiber rolls at the other end.
 12. The system of claim 1, wherein said CO₂ conversion chamber and said graphite-oxygen separation chamber are fluidly linked together using two connecting pipes, and wherein both chambers use an electrolyte solution that is prepared by dissolving potassium hydroxide (KOH), silicon (Si), and silicic acid soda (Na₂O, nSiO₂, H₂O) in a volume of water resulting in a high pH solution.
 13. The system of claim 1, wherein said graphite-oxygen separation chamber comprises a hollow, cylindrical filter drum made of layers of synthetic silicon resin, glued together with silicon resin adhesive and perforated with a multiplicity of tubular filters, wherein each tubular filter is filled with loose fiberglass fibers at one end and tightly packed fiberglass fiber rolls at the other end.
 14. The system of claim 13, wherein during use of said system a filmy, gelatinous substance comprising a mixture of graphite, oxygen, un-processed CO₂ and electrolyte solution is produced by said conversion chamber; said filmy gelatinous substance is directed to the center of said filter drum; fresh electrolyte solution from an electrolyte solution tank is released to the center of said filter drum via a washing pipe; and said filter drum is spun at centrifuge speed.
 15. The system of claim 14, wherein spinning of said filter drum creates an inductive environment in said filter drum., whereby graphite in the filmy, jelly substance is attracted and migrated to loose fibers of the tubular filters, wherein graphite is washed off from tubular filters in graphite-oxygen separation chamber with electrolyte solution and directed to electrolyte solution storage tank and oxygen in the filmy, jelly like substance passes through tubular filters and is then directed to an oxygen and un-processed CO₂ collection tank.
 16. A system for purifying polluted air, comprising an air pollutant conversion chamber comprising at least one pipe wherein during use said pipe contains electrolyte solutioni and is rotated at high speed and becomes inductive so that upon introduction of polluted air to said pipe a filmy, gelatinous substance is produced containing constituents of at least one air pollutant, un-processed air pollutant, and electrolyte solution; and in fluid connection therewith, a pollutant-gas separation chamber comprising a filter drum that separates a solid pollutant constituent from gas in said filmy, gelatinous substance under inductive condition by spinning said filter drum at centrifuge speed.
 17. The system of claim 17, further comprising a gas delivery network that introduces, circulates, regulates and maintains air pollutant and gas pressure at desired levels throughout the air pollution conversion system; a liquid delivery network that introduces, circulates, regulates and maintains pressure of fresh and spent electrolyte solution as well as colloid of air pollutant and electrolyte solution at desired levels throughout the air pollution conversion system; and a network of electrical devices which include motors, pumps, electromagnetic solenoids, valves, nozzles that control, maintain the flow and pressure of gas and liquid in the air pollution conversion system.
 18. The system of claim 16, wherein during use of said system polluted air and electrolyte solution are introduced to said pipe, said polluted air is mixed with said electrolyte in said pipe, and a jelly, filmy substance is generated that comprise of a plurality of constituents of a target air pollutant, hydrogen or oxygen gas or both, un-processed air pollutant, and electrolyte solution.
 19. The system of claim 18, wherein use of said system further comprises directing said jelly, filmy substance generated in the air pollutant conversion chamber to the pollutant-gas separation chamber using pressure created by spinning said pipe in said air pollutant conversion chamber.
 20. The system of claim 19, wherein use of said system further comprises directing said filmy, gelatinous substance to the center of said filter drum; injecting fresh electrolyte solution from an electrolyte solution tank to the center of said filter drum via a washing pipe; and spinning said filter drum at centrifuge speed.
 21. The system of claim 20, wherein said spinning of said filter drum that contains a mixture of constituents of at least one air pollutant, oxygen or hydrogen gas or both, un-processed air pollutant, and electrolyte solution creates an inductive environment in the filter drum, whereby element of the air pollutant in the filmy, jelly substance will be attracted and migrated to loose fibers of tubular filters in said filter drum, and, under such inductive condition gas in the filmy, jelly like substance passes through said tubular filters.
 22. A method for separating carbon dioxide to particulate carbon and oxygen, comprising processing carbon dioxide in the system of claim 1, thereby producing separated particulate carbon and oxygen gas. 